NOVEL HIGH-RATE MANUFACTURING PROCESS FOR MULTIFUNCTIONAL THERMOPLASTIC COMPOSITES

In pursuit of enhanced fuel economy, the automotive industry is exploring the substitution of metal components with lightweight polymer composites. These components must withstand elevated static loading and crash performance, while ideally offering added functionalities and reduced weight. To tackle these challenges, this research presents an innovative manufacturing method aimed at reducing costs and cycle times associated with continuous fiber polymer composites. This method involves producing a linear thermoplastic composite rod known as M-TOW (Multi-tow), which can be molded into intricate shapes to serve as tailored structural reinforcement in hybrid-molded parts. The research encompasses the processing of M-TOW, with a focus on predicting consolidation using Darcy’s law, integrating functional components for thermal and electrical conductivity using overbraided metallic wire or sensing using optical fibers, and its application in real-world scenarios. These advancements showcase the versatility and potential of M-TOW in high-rate continuous fiber manufacturing, paving the way for multifunctional hybrid molded structures.